Are Automakers Racing Ahead with Next-Generation Electric Drives?

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The global push toward electric mobility is gaining tangible momentum as major automakers unveil ambitious electric drive innovations set to reshape the automotive landscape. In Austria, BMW has officially begun series production of its sixth-generation electric drive systems at the Steyr plant, marking a pivotal shift for the company’s future vehicle platforms. Meanwhile, Changan’s Deepal brand in China is preparing to debut what it claims will be the world’s most integrated and efficient electric drive system in 2026, signaling a strategic leap in EV technology.

BMW Steyr: Pioneering the Gen6 Electric Drive

At BMW’s Plant Steyr, a facility long known for producing internal combustion engines, the production of Gen6 electric motors has commenced. The plant will manufacture key components including rotors, stators, transmissions, and inverters for the company’s upcoming Neue Klasse lineup. “The launch of the Gen6 electric engine is more than a production ramp-up; it is a firm commitment to Europe, technology, and the future,” said Klaus von Moltke, Plant Director at Steyr.

The Gen6 system features an 800-volt architecture and silicon carbide semiconductors, reducing energy loss by 40 percent, costs by 20 percent, and weight by 10 percent compared to previous generations. Combined with high-voltage batteries, BMW projects the first Neue Klasse models could achieve ranges up to 800 kilometers.

BMW is investing over €1 billion in Steyr’s EV capabilities through 2030, with the plant’s workforce gradually transitioning toward electric mobility production. The move underscores BMW’s commitment to scaling EV production while maintaining its European manufacturing base.

Digital Twin Integration and Real-Time Efficiency Optimization in E-Motor Development

Digitized testing ecosystem designed to optimize electric drive systems (e-motors). At its core, the system bridges the gap between physical hardware and digital simulation, a process essential for developing next-generation technology like BMW’s Gen6 electric drives or Changan’s integrated units. The process begins with MoBeLIV software tools, which allow engineers to design and simulate motor parameters. This digital intent is then tested on a physical e-motor setup, where high-precision sensors measure torque (Nm), rotational speed (rpm), and electrical inputs (U/I) with an accuracy of $0.015\%$.

The heart of the operation is the HBK data acquisition system, a scalable hardware hub that can manage up to 51 power channels. This system uses real-time communication protocols like CAN and EtherCAT to transfer results instantly to control systems, ensuring that the motor's behavior aligns with the predicted "Digital Twin". A key feature shown is the Virtual Vehicle model, which runs "in the loop" to replicate real driving conditions such as hills or stop-and-go traffic allowing the motor to be validated for durability and efficiency before it is ever installed in a physical chassis. Finally, all data is fed into advanced analysis workstations to create efficiency maps and stored data for public equations, ensuring the drive system meets the high-performance benchmarks required for the 2026 EV market

Changan Deepal: Aiming for Global EV Leadership

In parallel, China’s Changan Deepal brand is set to make waves with its forthcoming Force Super Integrated Electric Drive, slated for 2026. The company positions this system as the “most integrated and efficient” electric drive globally.

The announcement coincides with Deepal’s rapid expansion strategy, which includes rolling out a new model every two weeks for the next two months and introducing 30 mainstream and differentiated models over five years. Beyond electric drives, Deepal is integrating advanced features such as 3nm automotive-grade cockpit chips and standard LiDAR across its models, reflecting a holistic approach to next-generation EV design. Deepal’s upcoming battery systems also promise enhanced safety, including fire-free performance under high-speed collisions, reinforcing the brand’s commitment to both efficiency and reliability.

Precision Hardware-in-the-Loop Testing for Next-Generation Electric Powertrains

The core of this system is the HBK data acquisition system, which acts as a scalable bridge capable of handling up to 51 power channels. This hardware captures critical high-speed signals such as torque (Nm), speed (rpm), and electrical values (U/I) with an accuracy of 0.015%.

The process begins with MoBeLIV software tools, where engineers optimize motor parameters digitally. These designs are validated through Hardware-in-the-Loop (HiL) testing, which uses a Virtual Vehicle model to simulate real-world driving conditions. This ensures that hardware like BMW’s new electrically excited synchronous motors (EESM) or Changan’s 160 kW integrated units can be tested for efficiency and durability before being installed in a vehicle.

Industrial communication protocols like CAN and EtherCAT enable "Real-Time Result Transfer" to control systems, allowing the motor to behave like a "Digital Twin" of its simulated counterpart. Finally, the collected data is processed in analysis workstations to create efficiency maps, which are vital for achieving the 20% increase in overall vehicle efficiency targeted by the BMW Gen6 system.

Long-Term Market Impact: NMSC Perspective

Next Move Strategy Consulting sees these developments as indicative of a pivotal shift in the electric drives market. BMW’s methodical ramp-up in Europe demonstrates the importance of scaling production while optimizing system efficiency, setting a benchmark for high-performance EVs in mature markets.

Meanwhile, Changan Deepal’s aggressive expansion and integrated EV strategy highlights the competitive pressure in emerging markets, particularly China, where innovation cycles are accelerating. NMSC anticipates that integrated electric drive systems combining efficiency, safety, and modularity will become a critical differentiator, influencing global supply chains, investment priorities, and cross-border technology collaboration.

Collectively, these trends suggest a future in which automakers not only compete on vehicle performance but also on the sophistication and efficiency of their electric drive systems—creating opportunities for technology partnerships, cost optimization, and global standardization of EV components.

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